Paper pallets

ABSTRACT

According to the teaching of the present invention, laminated sheet paper is used to constitute components making up the carrying surface and horizontal runners ( 12 ) of a paper pallet ( 10 ). A plurality of horizontal runners ( 12 ) is disposed and bonded to the underside of a flat sheet ( 11   c ) or a plurality of parallel spaced apart elongate elements ( 11   a,    11   b ). The elongate elements can be T-shaped ( 11   a ) or flat ( 11   b ). A T-shaped elongate element ( 11   a ) can be made from two L-shaped elongate elements, correspondingly disposed and suitably bonded together. In the case of T-shaped elongate elements ( 1  Ia), top portions of each horizontal runner ( 12 ′) and orthogonal core insert ( 14 ′) are cut ( 19 ) at those positions where the T-shaped elongate elements ( 11   a ) are placed. Each horizontal runner ( 12 ) is substantially hollow and rectangular in shape and is constituted from at least one channel member ( 15, 13, 17 ) and a plurality of orthogonal core inserts ( 14 ) vertically disposed therein. The present invention teaches five designs of the horizontal runners ( 12   a - 12   e ) and three designs of the components making up the carrying surface. Twelve embodiments of the paper pallets ( 10   a - 101 ) made according to the present invention include two-way pallets and four-way pallets.

TECHNICAL FIELD

The present invention relates generally to paper pallets as goodscarrying equipment. Specifically, it relates to pallets made fromlaminated sheet paper and various designs of their components making upthe carrying surface and horizontal runners.

BACKGROUND ART

As goods carrying equipment, pallets are traditionally made from wood,plastic or paper. Traditional paper design makes use of honey-combstructure or corrugated paper structure, to give a paper pallet itsstructural rigidity. There have been numerous attempts to improve thestrength and design of paper pallets.

U.S. Pat. No. 2,559,930 discloses a pallet comprising supports in theform of hollow rectangular paper tubes arranged in spaced parallelrelationship, rectangular inserts arranged to fit tightly into the endsof said tubes, and stiff paper sheets secured to either side of saidtubes, both the tubes and the inserts being formed of paper wound inlayers bonded together, and the axes of the tubes and inserts beingarranged at right angles to one another.

U.S. Pat. No. 2,928,638 discloses a portable pallet and method offabricating it. The pallet comprises a pair of opposed sheets ofpaperboard each folded and shaped with provisions of a plurality ofalternate upper and lower flat planar sections and intervening verticalwall sections forming channels with the open side of the successivechannels being alternately at the top and bottom there being a pluralityof such channels at each side, the sheets being arranged adjacent withthe facing channels in one sheet at right angles to the facing channelsin the other sheet; pedestals mounted in the communicating channelspaces where opposed open channels cross, the pedestals extending to thebottoms of the corresponding opposed channels with the pedestal endengaging the corresponding planar section, and means securing the sheetsand pedestals together in fixed relation.

U.S. Pat. No. 4,714,026 discloses a pallet for material handling. Itcomprises a deck board and a plurality of legs which are fixed to theunder surface of the deck board with specified spacing. The deck boardis constituted of laminated corrugated fiberboard, and each of the legsis formed by a square-tubular frame, which is made of a corrugatedfiberboard, and in which a pad or pads made of plastic resin isinserted. The deck board of a durable light weight structure has aroughened top surface to prevent slips of a cargo. The legs are soconstructed to support heavy load without deforming and collapse, andare designed to prevent absorption of moisture.

U.S. Pat. No. 5,285,731 discloses a corrugated paperboard pallet. Itincludes a base member having first and second pairs of opposite sidesand a plurality of column-shaped support members secured to the bottomside of the base member. The support members have apertures at opposingends for receiving flaps from the base member and support blocks, so asto secure the support members to the base member and to provideadditional strength to the pallet, respectively. This pallet design canbe conveniently shipped and stored until ready for use, and can beentirely assembled by the user.

U.S. Pat. No. 5,329,861 discloses an improved, lightweight, recyclable,nearly completely paper pallet. The pallet is made of a honeycomb paperbase and honeycomb paper support runners or blocks. The blocks areprotected and significantly strengthened by a rigid paper cap. The base,runners, blocks, and cap may also have a protective liner, such aspolyethylene, or be otherwise treated to enhance water and moistureresistance.

SUMMARY OF THE INVENTION

The present invention has therefore, as a primary object to providepallets made from laminated sheet paper, such that they can be used as agoods carrying equipment.

Another object of the present invention is that paper pallets must beeconomical, light weight and structurally strong.

Yet, another object of the present invention is that designs of paperpallets must be simple and versatile to meet the varying needs of users.

These and other objects are achieved in that a plurality of horizontalrunners being disposed and bonded to the underside of a flat sheet or aplurality of parallel spaced apart elongate elements. The elongateelements can be flat or T-shaped. Each horizontal runner issubstantially hollow and rectangular in shape and is constituted fromone or more channel members and a plurality of orthogonal core insertsvertically disposed therein. Where an integral U-channel or C-channelmember is not available, it can be constituted from two L-shapedelongate members correspondingly disposed and suitably bonded. In thecase of T-shaped elongate elements, the top portions of the horizontalrunners and orthogonal core inserts are cut at those positions where theT-shaped elongate elements are placed.

Twelve embodiments of the paper pallets made according to the presentinvention include two-way pallets and four-way pallets. Three horizontalrunners are used to construct a two-way pallet. To construct a four-waypallet, the middle portion of the bottom half of a horizontal runner isleft vacant, with two spaced apart short supporter U-channel membersdisposed towards both ends.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the present invention may be more readily understood, thefollowing description is given, by way of examples, of twelve specificembodiments of a paper pallet made in accordance to the presentinvention. Reference is made to the accompanying drawings, in which:

FIG. 1 is a perspective view of a first embodiment of a paper palletmade in accordance to the present invention.

FIG. 2 is a perspective view of a second embodiment of a paper palletmade in accordance to the present invention.

FIG. 3 is a perspective view of a third embodiment of a paper palletmade in accordance to the present invention.

FIG. 4 is a perspective view of a fourth embodiment of a paper palletmade in accordance to the present invention.

FIG. 5 is a perspective view of a fifth embodiment of a paper palletmade in accordance to the present invention.

FIG. 6 is a perspective view of a sixth embodiment of a paper palletmade in accordance to the present invention.

FIG. 7 is a perspective view of a seventh embodiment of a paper palletmade in accordance to the present invention.

FIG. 8 is a perspective view of an eighth embodiment of a paper palletmade in accordance to the present invention.

FIG. 9 is a perspective view of a ninth embodiment of a paper palletmade in accordance to the present invention.

FIG. 10 is a perspective view of a tenth embodiment of a paper palletmade in accordance to the present invention.

FIG. 11 is a perspective view of an eleventh embodiment of a paperpallet made in accordance to the present invention.

FIG. 12 is a perspective view of a twelfth embodiment of a paper palletmade in accordance to the present invention.

FIG. 13 a shows a perspective view of a first design of a horizontalrunner made in accordance to the present invention.

FIG. 13 b shows a perspective view of the horizontal runner as shown inFIG. 13 a, with a plurality of cuts on its top portion.

FIG. 14 a shows a perspective view of a second design of a horizontalrunner made in accordance to the present invention.

FIG. 14 b shows a perspective view of the horizontal runner as shown inFIG. 14 a, with a plurality of cuts on its top portion.

FIG. 15 a shows a perspective view of a third design of a horizontalrunner made in accordance to the present invention.

FIG. 15 b shows a perspective view of the horizontal runner as shown inFIG. 15 a, with a plurality of cuts on its top portion.

FIG. 16 a shows a perspective view of a fourth design of a horizontalrunner made in accordance to the present invention.

FIG. 16 b shows a perspective view of the horizontal runner as shown inFIG. 16 a, with a plurality of cuts on its top portion.

FIG. 17 a shows a perspective view of a fifth design of a horizontalrunner made in accordance to the present invention meant for a four-waypallet.

FIG. 17 b shows a perspective view of the horizontal runner as shown inFIG. 17 a, with a plurality of cuts on its top portion.

DISCLOSURE OF INVENTION Detailed Description of the Invention

According to the teaching of the present invention, layers of laminatedsheet paper are suitably bonded together to the required dimensions.

A paper pallet (10) comprises essentially a carrying surface on top ofthree parallel spaced apart horizontal runners (12). The total number ofembodiments of the paper pallet (10) according to the teaching of thepresent invention depends on the combination use of the designs of thecomponents making up the carrying surface and the horizontal runners(12). In the following description, only twelve embodiments aredisclosed.

For ease of description, common component making up the carrying surfaceis numbered ‘11’ while its different designs are marked ‘a’, ‘b’ and ‘c’after the numeral ‘11 ’. Common component of horizontal runners isnumbered as ‘12 ’. Alphabets ‘a’ to ‘e’ are added after the numeral ‘12’ to indicate different designs of the horizontal runners (12). ‘a” to‘e” are added after the numeral ‘12 ’ to indicate different designs ofthe horizontal runners (12) with cuts (19) on the top portions of thehorizontal runners (12). Alphabets ‘a’ to ‘1 ’ are used to differentiatethe twelve embodiments of the paper pallets (10).

There are three designs of the components making up the carryingsurface, which is placed essentially across or perpendicularly to thelongitudinal axis of the horizontal runners (12). A first design of thecomponents making up the carrying surface comprises a plurality ofT-shaped elongate elements (11 a), which are parallel spaced apart (seeFIGS. 1, 3, 5, 7 and 9). The T-shaped elongate elements (11 a) areperpendicular to the horizontal runners (12). Where T-shaped elongateelements (11 a) are employed to fabricate a carrying surface, aplurality of cuts (19) is made to the top portions of the horizontalrunners (12) so as to receive the protruding section of the T-shapedelongate elements (11 a). A T-shaped elongate element (11 a) can be madefrom two L-shaped elongate elements, suitably bonded together by glueand/or staples. A second design of the components making up the carryingsurface comprises a plurality of flat elongate elements (11 b), whichare parallel spaced apart (see FIGS. 2, 4, 6, 8 and 10). The flatelongate elements (11 b) are perpendicular to the horizontal runners(12). A third design of the component making up the carrying surfacecomprises simply a flat sheet (11 c) (see FIGS. 11 and 12). The flatsheet (11 c) covers all three horizontal runners (12).

Essentially, three horizontal runners (12) are used to supportcomponents making up the carrying surface of a paper pallet (10). FIGS.1-4, 7-10 and 12 each depicts essentially a two-way pallet. FIGS. 5, 6and 11 each depicts a four-way pallet, where the middle portion of thebottom half of each horizontal runner (12 e) is left vacant and theupper half of each horizontal runner (12 e) is supported by two spacedapart short supporter U-channel members (17).

Five possible designs of the horizontal runners (12 a-12 e) are taughtaccording to the teaching of the present invention.

It is important to note that the load bearing function of a paper pallet(10) is carried by a plurality of orthogonal core inserts (14) standingvertically therein each horizontal runner (12). The axis of eachorthogonal core insert (14) is perpendicular to the longitudinal axis ofthe horizontal runner (12). At least one channel member (15, 13, 17)allows these orthogonal core inserts (14) to be easily contained, toconstitute a rectangular design of the horizontal runner (12).Orthogonal core inserts (14) are used because their four faces allowbetter contact with other constituent components, for glue and/orstapling method to function more effectively.

According to the teaching of the present invention, each horizontalrunner (12) is substantially hollow and rectangular in shape. Therectangular profile of the horizontal runners (12) is substantiallydefined by one or more channel members (15, 13, 17) including aU-channel member (13, 17) or a C-channel member (15). Where an integralU-channel member (13, 17) or a C-channel member (15) is not available,the U-profile or C-profile can be constituted from two L-shaped elongatemembers correspondingly disposed and suitably bonded together.

As seen in FIG. 13 a, a first design of the horizontal runner (12 a),which is substantially rectangular, is formed from an inverted U-channelmember (13) disposed at its top and a bottom U-channel member (13). Aplurality of orthogonal core inserts (14) is vertically disposed inbetween the two U-channel members (13) along the length of thehorizontal runner (12 a). Two U-channel members (13) facilitate suchinsertion. The height of the horizontal runner (12 a) correspondssubstantially to the height of the orthogonal core inserts (14). Whenthe above horizontal runners (12 a) are used in conjunction with aplurality of T-shaped elongate elements (11 a), a plurality of cuts (19)is made to top portion of each horizontal runner (12 a′) and topportions of the orthogonal core inserts (14′) (FIG. 13 b). The number oforthogonal core inserts (14′) corresponds to the number of T-shapedelongate elements (11 a) used. It is important to note that theorthogonal core inserts (14′) are placed at these cut positions (19) tosupport the T-shaped elongate elements (11 a).

As seen in FIG. 14 a, a second design of the horizontal runner (12 b),which is substantially rectangular, is formed from a C-channel member(15) with a plurality of orthogonal core inserts (14) verticallydisposed in between its two horizontally facing flanges. The C-channelmember (15) comprises two horizontally facing flanges and a verticalflange along the length of the horizontal runner (12 b). The height ofthe C-channel member (15) corresponds substantially to the height of theorthogonal core inserts (14). When the above horizontal runners (12 b)are used in conjunction with a plurality of T-shaped elongate elements(11 a), a plurality of cuts (19) is made to top flange of each C-channelmember (15′) and the top portions of the orthogonal core inserts (14′)(FIG. 14 b). The number of orthogonal core inserts (14′) corresponds tothe number of T-shaped elongate elements (11 a) used. It is important tonote that the orthogonal core inserts (14′) are placed at these cutpositions (19) to support the T-shaped elongate elements (11 a).

As seen in FIG. 15 a, a third design of the horizontal runner (12 c),which is substantially rectangular, is formed from an inverted U-channelmember (13) disposed at its top and a bottom U-channel member (13). Aplurality of orthogonal core inserts (14), flanked by two flat panels(16) at its sides along the length of the horizontal runner (12 c), isvertically disposed in between the two U-channel members (13). Theheight of the rectangular horizontal runner (12 c) correspondssubstantially to the height of the orthogonal core inserts (14). Whenthe above horizontal runners (12 c) are used in conjunction with aplurality of T-shaped elongate elements (11 a), a plurality of cuts (19)is made to the top portion of each horizontal runner (12 c′) and the topportions of the orthogonal core inserts (14′) as well as the flat panels(16′) (FIG. 15 b). The number of orthogonal core inserts (14′)corresponds to the number of T-shaped elongate elements (11 a) used. Itis important to note that the orthogonal core inserts (14′) are placedat these cut positions (19) to support the T-shaped elongate elements(11 a).

As seen in FIG. 16 a, a fourth design of the horizontal runner (12 d),which is substantially rectangular, is formed from two embracingC-channel members (15 a, 15 b) (i.e. one big and one small) with aplurality of orthogonal core inserts (14) vertically disposed inside thesmall C-channel member (15 b). The orthogonal core inserts (14) areflanked by two flat panels (16) at its sides along the length of thehorizontal runner (12 d). The height of the small C-channel member (15b) corresponds substantially to the height of the orthogonal coreinserts (14). When the above horizontal runners (12 d) are used inconjunction with a plurality of T-shaped elongate elements (11 a), aplurality of cuts (19) is made to the top portion of each horizontalrunner (12 d′) and the top portions of the orthogonal core inserts (14′)as well as the flat panels (16′) (FIG. 16 b). The number of orthogonalcore inserts (14′) corresponds to the number of T-shaped elongateelements (11 a) used. It is important to note that the orthogonal coreinserts (14′) are placed at these cut positions (19) to support theT-shaped elongate elements (11 a).

In all possible runner design involving channel members (13, 15, 17),the orthogonal core inserts (14) vertically disposed therein can beflanked by at least one flat panel (16) along the length of thehorizontal runner (12 c, 12 d). The flat panels (16) further strengthenthe rigidity of the runner design. The above disclosed third and fourthdesigns can be considered as reinforced versions of the runner designs.

As seen in FIG. 17 a, a fifth design of the horizontal runner (12 e),which is substantially rectangular, is formed from a long invertedU-channel member (13) disposed at its top with two spaced apart shortsupporter U-channel members (17) disposed below towards both ends of thetop inverted U-channel member (13). Effectively, the middle portion ofthe bottom half of the horizontal runner (12 e) is left vacant, which ismeant to constitute a four-way pallet. The exact length of the middleportion to be left vacant can vary and be tailor-made to meet users'requirements. It is important to note that the middle portion of the topinverted U-channel member (13) that corresponds to the left vacantportion is inserted with a horizontal length of hollow core insert (18).The longitudinal axis of this hollow core insert (18) is parallel to thelongitudinal axis of the horizontal runner (12 e). This fifth design ofthe horizontal runner (12 e) is suitable for use to construct a four-waypallet. A plurality of orthogonal core inserts (14) is verticallydisposed in between the engaging U-channel members (13, 17). The heightof the rectangular horizontal runner (12 e) corresponds substantially tothe height of the orthogonal core inserts (14). When the abovehorizontal runners (12 e) are used in conjunction with a plurality ofT-shaped elongate elements (11 e), a plurality of cuts (19) is made tothe top portion of each horizontal runner (12 e′) and the top portionsof the orthogonal core inserts (14′) (FIG. 17 b). It is important tonote that the orthogonal core inserts (14′) and the horizontal length ofthe hollow core insert (18) are placed at these cut positions (19) tosupport the T-shaped elongate elements (11 a).

It is obvious to those skilled in the art that further modification canbe anticipated from the teaching of the above disclosure. For anexample, the paper pellet (10) can be further strengthened by attachingat least two support elements (20) to the bottom of the horizontalrunners (12) as shown in FIGS. 9 and 10.

1. (canceled)
 2. (canceled)
 3. A paper pallet comprising: a plurality ofhorizontal runners and components making up one carrying surface on topof the horizontal runners, wherein the horizontal runners and thecomponents making up the carrying surface are made from layers oflaminated sheet paper; each horizontal runner is substantially hollowand rectangular in shape with its longitudinal axis horizontallydisposed; each horizontal runner further comprising at least one channelmember and a plurality of orthogonal core inserts vertically disposedtherein; and the components making up the carrying surface include aplurality of parallel spaced apart T-shaped elongate elements which isdisposed perpendicularly on all the horizontal runners, and a pluralityof cuts is made to top portion of each horizontal runner and topportions of the orthogonal core inserts at appropriate positions wherethe T-shaped elongate elements are placed, whereby goods carried on topof the carrying surface are supported by the horizontal runnersunderneath.
 4. A paper pallet as in claim 3, wherein the horizontalrunner is formed from an inverted U-channel member disposed at its topand a bottom U-channel member, whereas a plurality of orthogonal coreinserts is vertically disposed in between the two U-channel membersalong the length of the horizontal runner, the height of the horizontalrunner corresponds substantially to the height of the orthogonal coreinserts.
 5. (canceled)
 6. A paper pallet as in claim 3, wherein thehorizontal runner is formed from one big and one small embracingC-channel members with a plurality of orthogonal core inserts verticallydisposed inside the small C-channel member, the height of the smallC-channel member corresponds substantially to the height of theorthogonal core inserts.
 7. A paper pallet as in claim 3, wherein theorthogonal core inserts vertically disposed therein the horizontalrunner are flanked by at least one flat panel along the length of thehorizontal runner.
 8. A paper pallet as in claim 3, wherein thehorizontal runner is formed from a long inverted U-channel memberdisposed at its top with two spaced apart short supporter U-channelmembers disposed below towards both ends of the top inverted U-channelmember, leaving an empty space in between the two short supporterU-channel members, whereas a plurality of orthogonal core inserts isvertically disposed in between the engaging U-channel members, theheight of the rectangular horizontal runner corresponds substantially tothe height of the orthogonal core inserts, such that the horizontalrunner is used to constitute a four-way pallet.
 9. A paper pallet as inclaim 8, wherein the middle portion of the top inverted U-channel memberof the horizontal runner that corresponds to the left vacant portion isinserted with a horizontal length of hollow core insert.
 10. A paperpallet as in claim 3, wherein the T-shaped elongate element is made fromtwo L-shaped elongate elements correspondingly disposed and suitablybonded together.
 11. A paper pallet as in claim 3, wherein the channelmember includes a C-channel member, which is made from two L-shapedelongate members correspondingly disposed and suitably bonded together.12. A paper pallet as in claim 3, wherein the channel member includes aU-channel member, which is made from two L-shaped elongate memberscorrespondingly disposed and suitably bonded together.